Seat construction

ABSTRACT

A seat in the form of an upholstered chair or sofa of modular construction having a skeletal frame to which molded side arms formed of reinforced rigid foam are secured, with a cushioned seat and a cushioned back rest carried by the skeletal frame and formed as modular pre-upholstered units, and wherein preupholstered side arm cushions overlie the rigid foam side arms and are secured thereto.

United States Patent 11 1 Korch 1 Sept. 18, 1973 SEAT CONSTRUCTION3,101,218 8/1963 Baermann 297 455 2,801,682 8 1957 Fridolph 5 356 [75]Invent i 18am, 3,614,159 10/1971 Christin 297/459 4 5 swltzerland3,233,253 2 1966 Cauvin 297/218 [73] Assignee: Burris Industries,Incorporated,

i Lincolmo N,C Primary Examiner-Casmir A. Nunberg Att D ld M. S It 22Filed: June 6, 1972 V e m 211 App]. No.2 260,137 57 ABSTRACT i A seat inthe form of an upholstered chair or sofa of [52] U.S.Cl 297/445,297/422, 297/440 a n r c n having a skeletal frame to which '[51] Int.Cl A476 7/20, A47c 7/14 molded side rm f rm d f r inf r d rigi foam re[58] Field of Search 297/218, 219, 418-422, secured, i a cushioned t anda u i n d a k 297/440, 445, 452, 455.458; 5/356, 360 rest carried by theskeletal frame and formed as modular pre-upholstered units, and whereinpreupholstered [56] References Cited side arm cushions overlie the rigidfoam side arms and i I UNITED STATES PATENTS Secured thereto- 3,298,741I 1/1967 Lepard, Jr. et al. 297/452 11 Claims, 19 Drawing FiguresPATENTED SEP 1 8 I973 SHEET 2 OF 5 PATENTED SE? I 8 i975 SHEET 3 OF 5PATENIEU SEP 1 81915 SHEEI t 0? 5 SEAT CONSTRUCTION This inventionrelates to seat constructions and more particularly to upholstered typefurniture which is constructed on the modular concept so as tofacilitate the assembly and manufacture thereof.

One of the primary objects of the invention is to take advantage ofexisting knowledge in the molding field and apply the same to furnitureconstructions to considerably reduce hand labor and the attendant highcosts thereof and at the same time to impart to the manufacturedfurniture enhanced structural characteristics. v

' Another object of the invention is to construct fumiture whereinvarious components thereof may be interchangeably utilized for chairs aswell as sofas thus permitting added flexibility in the manufacture offumiture dependent on varying market conditions.

Some of the objects of the invention having been stated, other objectswill be apparent as the description proceeds when taken in connectionwith the accompanying drawings in which:

FIG. 1 is a perspective view of a chair constructed in accordance withthis invention;

FIG. 2 is a rear elevational view of the chair,

FIG. 3 is a vertical sectional view taken along line 3-3 of FIG. 1;

FIG. 4 is another vertical sectional view taken along line 4--4 of FIG.3;

FIG. 5 is an exploded view of the chair of FIG. 1 with certain parts aswell as the upholstery covering omitted;

FIG. 6 is another exploded view of the chair of FIG. 1 with certain ofthe sub-assemblies of FIG. 5 shown pre-assembled;

FIG. 7 is a top perspective view of the cushioned seat inpre-upholstered condition ready for assembly into a chair;

FIG. 8 is a detailed fragmentary view with parts broken away of area 8of FIG. 7;

FIG. 9 is a bottomperspective view of the cushioned seat of FIG. 7;

FIG. 10 is a fragmentary perspective view illustrating the manner inwhich the lower portion of the preupholstered cushioned back rest issecured to the skeletal supporting frame;

FIG. 11 is a fragmentary vertical sectional view illustrating the mannerin which the rear portion of the preupholstered cushioned back rest issecured to the skeletal frame;

FIG. 12 illustrates the preparation of the side arm cushions for beingupholstered;

FIG. 13 is a fragmentary view illustrating the manner of securing adrawstring of a pre-upholstered side arm a cushion to an inner portionof the skeletal frame;

FIG. 14 is a fragmentary view of the pre-upholstered side arm cushionillustrating the manner in which the drawstring is positioned forforming pleats in the upholstery material;

FIG. 15 illustrates a partially assembled chair;

FIG. 16 is a fragmentary vertical sectional view illustrating the mannerin which the pre-upholstered side arm cushions are secured to'theunderlying side arms;

FIG. 17 is a perspective view of the molded back rest member; and

FIGS. 18 and 19 are front and rear elevational views of a sofaconstructed in accordance with the invention.

Referring now more specifically to the drawings and particularly to FIG.5, for a broad orientation of the invention, reference numeral 10indicates a skeletal frame having interconnected seating and back restframe components 11 and 12, respectively. To the opposite sides of theskeletal frame 10 are secured molded side arms 20 formed of reinforcedrigid foam, such as polyurethane. Suitably secured to the seatingcomponent 11 of the skeletal frame 10 is a modular cushioned seat 30,and secured to the back rest component 12 of the skeletal frame 10 is amodular cushioned back rest 40. Overlying the side arms 20 are side armcushions indicated at 50.

A description of the details of each of the components of the inventionwill now be given but not necessarily in the order of their fabricationor assembly. Referring now specifically to the skeletal frame 10, asbest illustrated in FIGS. 5 and 6, it will be noted that the seatingframe component 11 has a pair of spaced side members 11a and a front andrear transversely extending member 11b, 11c, respectively, connectingthe side members 11a. Overlying the front transversely extending member11b is an arcuate kick board 11d and extending from the upper surface ofthe front member 11b are a pair of dowel pins lle for aiding in securingthe modular cushioned seat 30 thereto. Suitably secured to and extendingupwardly from rear portions of side members 11a, are a pair of spacedback rest supporting members 12a which are interconnected by a pluralityof transversely extending members 12b. Overlying the rear surface of thetransversely extending members 12b and the rear ends of side members110, and suitably secured thereto, is an arcuately shaped member 12c,suitably formed of thin plywood, for example, which, as best shown inFIGS. 3 and 13, serves for presenting the desired shape to the lowerrear portion of the furniture and as a supportingsurface for securementof the upholstery material thereto.

Referring now more particularly to the molded side arms 20, as notedearlier, these side arms are formed of reinforced rigid foam with thereinforcement, as best shown in FIGS. 5 and 16, comprising an L-shapedinner member 20a and a plurality of vertical members 20b suitablysecured as by glue to the L-shaped reinforcing member 20a.

Referring now to the construction of the modular cushioned seat 30, asillustrated best in FIGS. 5 and 9, the modular cushioned seat comprisesa supporting sub-assembly'3l and a molded resilient foam cushion 32formed of a suitable plastic, such as polyurethane, overlying thesub-assembly 31 and being suitably secured thereto, as by adhesive. Thesupporting subassembly 31 comprises a rectangular frame 31a with aseries of spaced apart elongate pliable members or tapes 31b suitablysecured thereto in intersecting or crossing fashion, as best shown inFIG. 5. It will be noted that the front frame member 31a extendsdownwardly below the other frame members and serves to provide a back upor reinforcement for a downwardly depending lip portion 30a of themolded foam cushion 32, as best illustrated in FIG. 3.

Referring now to the modular cushioned back rest 40, it will be noted,as best illustrated in FIGS. 5, 6 and 11, that similar to the modularcushioned seat 30, a supporting sub-assembly 4-1 is provided which takesthe form of a rectangular frame 41a having a series of spaced apartelongate pliable members or tapes 41b suitably secured thereto. It willbe noted, as best shown in FIGS. 3 and 5, that uppermost frame member41a is curved longitudinally to provide the desired contour to the backof the chair. To the uppermost frame member 41a is secured a pre-shapedreinforcing member 42 preferably formed of reinforced fiberglass andwhich serves as an underlying reinforcing substrate for rear lip portion43a of a molded foam cushion 43, as best illustrated in FIG. 11.

Referring now to the construction of the side arm cushions 50, as bestillustrated in FIGS. 5, l2 and 16, the side arm cushions comprise moldedresilient foam cushions 51 of substantially inverted U-shape incrosssection. A reinforcing substrate member 52 also of substantiallyinverted U-shape configuration in crosssection is suitably secured tothe inner surface of the molded cushions 51 to lend rigidity thereto andto aid in securing the same to the side arms 20. The molded cushions 51,as best illustrated in FIG. 12, are each subjected to a cuttingoperation following the securing of the same to the underlyingreinforcing substrate 52, such cutting operation serving to provide cutlines C to almost completely separate the molded cushions 51 into threeserially arranged separate cushion units for the purpose of aiding inthe upholstering thereof and the forming of pleats or folds in theupholstered material between the severed foam units, to be explained ingreater detail hereinafter.

Referring now to FIGS. 13 and 14, it will be noted that the side armcushions 50 are upholstered with a suitable covering material M prior topositioning the same in straddling relationship over the side arms 20,with the upholstery material being suitably secured as by stapling tothe inner surface of the reinforcing substrate 52. Further, it will benoted that drawstrings 53 are incorporated in the upholstery material Mand positioned to overlie the cut lines C (FIG. 12) in the moldedcushion 51. One end 53a of each drawstring S3 is suitably secured to theinner surface of the substrate 52, as by stapling, for example, and theother end identified as 53b is secured to the inner surface of framemember 11a of the skeletal frame 10. As earlier noted, the drawstrings53 serve for imparting a pleat or fold in the upholstery material M topresent the appearance of three serially arranged cushions forming eachof the side arm cushions.

In addition to utilization of drawstrings 53 for securing the side armcushions 50 on the side arms 20, a plurality of transversely positionedfasteners are provided with the fasteners comprising cords 55 which aresuitably secured, as by stapling, to the reinforcing members 20b of theside arms 20 and, to the outer ends of which cords 55 are suitablysecured relatively large buttons 56, as best shown in FIGS. 15 and 16.To facilitate securing the cords 55 to the reinforcing members b, acorresponding number of holes 51a are provided in the molded cushions51, such holes normally extending entirely through the foam, with astaple of sufficient length being utilized to extend through theunderlying substrate 52 and penetrate into the reinforcing members 21b.As illustrated, four fastening inembers are provided for securing eachside arm cushion 50 to the respective supporting side arm 20.

Referring now to FIGS. 10 and 11, it will be noted that the modularcushioned back rest 40, after being upholstered, is suitably secured tothe skeletal frame by a pair of brackets 60 engaging the lowermosttransversely extending member 12b. As earlier noted, the contouredsubstrate member 42 underlies the rear lip portion 43a of the moldedcushion 43 and is suitably secured thereto as by adhesive. Asillustrated in FIG. 1 1, additional fastener means comprising cords 55and buttons 56 of the type previously described is utilized for securingthe downwardly depending rear lip portion 430 to the backside of theskeletal frame 10.

Modularcushioned seat 30, as earlier noted, is secured to the skeletalframe 10 by a pair of upstanding dowel pins lle extending from the frontmember 11b of the frame. In addition, bracket members (FIG. 3) areutilized with such bracket members being carried by the seatsub-assembly 31 and being secured to the front and rear transversemembers llb, 110 of skeletal frame 10.

For imparting a decorative pleat or fold in the upholstery material ofthe modular seat cushion 30, as best illustrated in FIGS. 7 to 9, itwill be noted that the molded cushion 32 is provided with a transverselyextending groove 32a in which is positioned a drawstring whichdrawstring is suitably secured to the upholstery material M to permitthe material to be drawn downwardly into the groove 320. As shown inFIG. 9, opposite ends of the drawstring 75 are suitably secured to theunderside of the seat sub-assembly 31, as by stapling, for example.

As already noted, the side arm cushions 50 and the modular cushionedseat and modular cushioned back rest are all separately assembled andpre-upholstered prior to assembly into the furniture item. Also, oncethe side arms 20 have been secured to the skeletal frame 10, the sidearms are upholstered with such upholstery material M normally includingan underlying resilient fibrous pad. A similar paddedupholstery materialis utilized for covering the front kick rail 1 1d of the skeletal frame,as well as the contoured rear frame member 120. Following the upholsteryof the assembled side arms 20 and skeletal frame 10, the pre-upholsteredside arm cushions 50 are positioned on top of the side arms 20 andsecured thereto as previously described. It is to be noted, as bestshown in FIGS. 4 and 6, that the side arm cushions 50 are so shapedrelative to the side arms 20 as to be matingly and straddlinglypositioned thereon. Further, it will be noted that the side arms 20 havetapered upper end portions for facilitating reception of the side armcushions thereon in overlying straddling relationship.

Following securement of the side arm cushions 50 to the side arms 20,the modular cushioned seat 30 is secured to the skeletal frame in amanner as previously described and, finally, the modular cushioned backrest 40 is assembled.

Referring now to FIG. 17, the molded back rest cushion 43 isillustrated, which is readily utilized in chairs and sofa constructions.To standardize molding, the molded cushion 43 is formed with opposingwing portions 43b which serve for presenting the desired flaredappearance to the back of the chair, as best illustrated in FIG. 2.However, in utilizing such molded foam cushion in forming a sofa, of thethree cushion type, as illustrated in FIG. 18 and 19, both the wingportions 43b are severed in forming the middle cushion of the sofa, andin forming the end cushions, one of the wings 43b is severed from eachcushion. This is readily apparent when viewing the back of the sofa, asillustrated in FIG. 19.

It will thus be understood that from the foregoing detailed descriptionthe instant invention permits the obtaining of chair and sofaconstructions of considerably high quality while utilizing pre-assembledmodular components to facilitate economical mass production of thefurniture.

In the drawings and specification there has been set forth a preferredembodiment of the invention and, although specific terms are employed,they are used in a generic and descriptive sense only and not forpurposes of limitation.

That which is claimed is:

1. A seat of modular construction comprising a skeletal frame havinginterconnected seating and back rest frame components, separately formedside arms of reinforced rigid foam connected to opposite sides of saidskeletal frame and having upwardly extending rear portions engagingupper side portions of said skeletal frame, at least one modularcushioned seat and one modular cushioned back rest carried by saidskeletal frame, each modular cushioned seat and modular cushioned backrest comprising a supporting sub-assembly and resilient foam overlyingand connected to said supporting sub-assembly, and side arm cushionscomprising resilient foam secured to a reinforcing substrate, said sidearrn cushions overlying and carried by said side arms and extendingdownwardly a predetermined extent along opposite sides thereof.

2. A seat according to claim 1, wherein said skeletal frame is of alength suitable for a sofa, and a plurality of modular cushioned seatsand modular cushioned back rests are carried by said skeletal frame.

3. A seat according to claim 1, wherein said supporting sub-assembly foreach modular cushioned seat and modular cushioned back rest comprises anelongate frame unit and a series of spaced apart elongate pliablemembers secured to said frame unit and extending lengthwise thereof.

-4. A seat according to claim 1, wherein said side arms have taperedupper portions of a smaller width dimension than lower portions thereofand wherein said side arm cushions are matingly and straddlinglypositioned on said tapered portion of said side arms.

,5. A seat according to claim 1, wherein fastening means are providedfor interconnecting said side arm cushions to said side arms, saidfastening means extending through outer portions of said side armcushions and into upper portions of said side arms.

6. A seat according to claim 1, wherein said side arm cushions comprisemolded resilient foam of substantially inverted U-shape incross-sectionand wherein said reinforcing substrate is secured to said foam andextends along the inner surface of the foam between the legs thereofdefined by the substantially U-shape configuration.

7. A seat according to claim 1, wherein said side arm cushions eachcomprise an elongate series of resilient foam pads positioned in side byside relation and each being substantially inverted U-shape incross-section,

and an elongate covering overlying each series of foam pads, saidcovering including transversely arranged drawstrings cam'ed thereby forpleatingly positioning and maintaining portions of the covering betweenadjacent foam pads of the series.

8. A seat according to claim 7, wherein fibrous padding is positionedbetween each series of foam pads and said overlying covering.

9. A seat of modular construction comprising a skeletal frame havinginterconnected seating and back rest frame components, separately formedside arms formed of reinforced rigid foam connected to opposite sides ofsaid skeletal frame and having upwardly extending rear portions engagingupper side portions of said skeletal frame, at least one modularcushioned seat and one modular cushioned back rest carried by saidskeletal frame, said modular cushioned seat comprising resilient foamhaving integrally formed therewith a downwardly depending frontal lipportion overlying frontal portions of the skeletal frame, said modularcushioned back rest comprising resilient foam having integrally formedtherewith a downwardly depending rear lip portion overlying upper rearportions of the skeletal frame, and side arm cushions comprisingresilient foam secured to a reinforcing substrate, said side armcushions overlying and carried by said side arms and extendingdownwardly a predetermined extent along opposite sides thereof.

10. A seat according to claim 9, wherein a reinforcing substrate issecured to the upper rear portion of said skeletal frame underlying saidresilient foam rear lip portion for reinforcing the same.

1 l. A seat of modular construction comprising a skeletal frame havinginterconnected seating and back rest frame components, side arms formedof reinforced rigid foam and having tapered upper portions of a smallerwidth dimension than lower portions thereof, said side arms beingconnected to opposite sides of said skeletal frame and having upwardlyextending rear portions engaging upper side portions of said skeletalframe, at least one modular cushioned seat and one modular cushionedback rest carried by said skeletal frame, each modular cushioned seatand modular cushioned back rest comprising a supporting sub-assembly andresilient foam overlying and connected to said supporting sub-assembly,and side arm cushions matingly and straddlingly positioned on saidtapered portion of said side arms and extending downwardly apredetermined extent along opposite sides thereof.

1. A seat of modular construction comprising a skeletal frame havinginterconnected seating and back rest frame components, separately formedside arms of reinforced rigid foam connected to opposite sides of saidskeletal frame and having upwardly extending rear portions engagingupper side portions of said skeletal frame, at least one modularcushioned seat and one modular cushioned back rest carried by saidskeletal frame, each modular cushioned seat and modular cushioned backrest comprising a supporting sub-assembly and resilient foam overlyingand connected to said supporting sub-assembly, and side arm cushionscomprising resilient foam secured to a reinforcing substrate, said sidearm cushions overLying and carried by said side arms and extendingdownwardly a predetermined extent along opposite sides thereof.
 2. Aseat according to claim 1, wherein said skeletal frame is of a lengthsuitable for a sofa, and a plurality of modular cushioned seats andmodular cushioned back rests are carried by said skeletal frame.
 3. Aseat according to claim 1, wherein said supporting sub-assembly for eachmodular cushioned seat and modular cushioned back rest comprises anelongate frame unit and a series of spaced apart elongate pliablemembers secured to said frame unit and extending lengthwise thereof. 4.A seat according to claim 1, wherein said side arms have tapered upperportions of a smaller width dimension than lower portions thereof andwherein said side arm cushions are matingly and straddlingly positionedon said tapered portion of said side arms.
 5. A seat according to claim1, wherein fastening means are provided for interconnecting said sidearm cushions to said side arms, said fastening means extending throughouter portions of said side arm cushions and into upper portions of saidside arms.
 6. A seat according to claim 1, wherein said side armcushions comprise molded resilient foam of substantially invertedU-shape in cross-section and wherein said reinforcing substrate issecured to said foam and extends along the inner surface of the foambetween the legs thereof defined by the substantially U-shapeconfiguration.
 7. A seat according to claim 1, wherein said side armcushions each comprise an elongate series of resilient foam padspositioned in side by side relation and each being substantiallyinverted U-shape in cross-section, and an elongate covering overlyingeach series of foam pads, said covering including transversely arrangeddrawstrings carried thereby for pleatingly positioning and maintainingportions of the covering between adjacent foam pads of the series.
 8. Aseat according to claim 7, wherein fibrous padding is positioned betweeneach series of foam pads and said overlying covering.
 9. A seat ofmodular construction comprising a skeletal frame having interconnectedseating and back rest frame components, separately formed side armsformed of reinforced rigid foam connected to opposite sides of saidskeletal frame and having upwardly extending rear portions engagingupper side portions of said skeletal frame, at least one modularcushioned seat and one modular cushioned back rest carried by saidskeletal frame, said modular cushioned seat comprising resilient foamhaving integrally formed therewith a downwardly depending frontal lipportion overlying frontal portions of the skeletal frame, said modularcushioned back rest comprising resilient foam having integrally formedtherewith a downwardly depending rear lip portion overlying upper rearportions of the skeletal frame, and side arm cushions comprisingresilient foam secured to a reinforcing substrate, said side armcushions overlying and carried by said side arms and extendingdownwardly a predetermined extent along opposite sides thereof.
 10. Aseat according to claim 9, wherein a reinforcing substrate is secured tothe upper rear portion of said skeletal frame underlying said resilientfoam rear lip portion for reinforcing the same.
 11. A seat of modularconstruction comprising a skeletal frame having interconnected seatingand back rest frame components, side arms formed of reinforced rigidfoam and having tapered upper portions of a smaller width dimension thanlower portions thereof, said side arms being connected to opposite sidesof said skeletal frame and having upwardly extending rear portionsengaging upper side portions of said skeletal frame, at least onemodular cushioned seat and one modular cushioned back rest carried bysaid skeletal frame, each modular cushioned seat and modular cushionedback rest comprising a supporting sub-assembly and resilient foamoverlying and connected to said supporting sub-assembly, and side armcushionS matingly and straddlingly positioned on said tapered portion ofsaid side arms and extending downwardly a predetermined extent alongopposite sides thereof.